Selector valve for use in completion operations

ABSTRACT

A ball-type selector valve is rotatably supported in a housing, for rotation therein between an open position, aligning a flow passage in the ball valve with a bore of the housing, to direct the flow of fluid therethrough and a closed position, wherein the flow passage is misaligned with the housing bore, for blocking the flow of fluid therethrough. The ball is rotated by a rack and pinion system. The ball is rotated about the pinion to align and misalign the flow passage with the bore when the rack is moved axially with an upper portion of the housing to which it is connected.

FIELD

Embodiments described herein relate to means for diverting fluid flow between fluid paths within and to outside a downhole tool to permit a variety of operations without tripping the downhole tool from a wellbore.

BACKGROUND

It is well known in completion operations to convey bottomhole assemblies (BHA) into a wellbore, the BHA having a variety of components capable of performing different functions related to completion of the wellbore. By way of example, BHA's are known to comprise abrasive jet cutting tools for cutting perforations through casing as well as tools for delivering treatment fluid, from within the BHA through pre-existing ports in the casing or through the cut perforations, into the formation for treatment thereof. Generally such BHA are deployed using coiled tubing or, alternatively, jointed tubulars.

To permit use of the various tools, without tripping the BHA from the wellbore, it is also known to divert fluid from the bore of the BHA to each of the various tools, such as by dropping an obturator, including but not limited to a dart, plug or ball, into a ball seat located below the desired tool to block the flow path through the bore of the BHA therebelow. After the bore below is isolated, fluid delivered through the bore is delivered through ports thereabove, such as through ports or nozzles in the jet cutting tool or through ports in a fracturing head.

As taught in U.S. Pat. No. 7,059,407 to ExxonMobil Upstream Research Company, a coiled-tubing deployed BHA may include a sub containing a circulation port sub that may provide a flow path to wash debris from above an inflatable, re-settable packer or provide a flow path to inject fluid downhole using the coiled tubing. The circulation port sub contains a valve assembly that actuates the circulation port and the upper equalization port. The upper equalization port may be connected to a lower equalization port via tubing through the inflatable, re-settable packer. Both the circulation port and the upper equalization port would preferably be open in the “running position”, thereby allowing pressure communication between the internal coiled-tubing pressure and the coiled tubing by casing annulus pressure. The “running position” refers to the situation where all components in the BHA possess a configuration that permits unhindered axial movement up and down the wellbore. The lower equalization port located below the inflatable, re-settable packer is always open and flow through the equalization ports is controlled by the upper equalization port. The circulation and equalization ports can be closed simultaneously by placing a slight compressive load on the BHA. Thus, cycling the BHA opens and closes ports to actuate components of the BHA without the need for ball seats which would narrow the bore.

As is taught in CA 2,820,704, CA 2,873,541 and CA 2,856,184 to NCS Oilfield Services Canada, Inc., of Calgary, Alberta, Canada, a pull-type sliding, selector valve is known wherein in an open frac position, ports in a mandrel are aligned with ports in an outer sleeve. Weight applied to the tubing string causes the mandrel to telescope into the outer sleeve for aligning the ports, as guided by a J-slot. A packer and slips therebelow are caused to set and seal the casing bore therebelow. Fluid delivered through the tubing string and BHA bore exits the ports in the outer sleeve. An equalization valve is closed in this position. When tension is applied to the tubing string, by pulling upwardly thereon, the frac valve is closed as the ports in the mandrel and the sleeve are axially misaligned. The equalization port opens and the packer and anchor are unset. The BHA can then be moved to another position in the wellbore.

There is interest for completion tools which allow functionality to be selected when the tools are deployed in the wellbore and without having to trip the tools from the wellbore.

SUMMARY

A ball-type selector valve is rotatably supported in a bore of a downhole tool and/or bottomhole assembly (BHA). The selector valve has a and axial fluid passage formed therethrough that is aligned, through rotation of the ball valve, with the tool bore for allowing fluid to pass therethrough. When required, the ball valve is rotated to misalign the axial fluid passage therein with the tool bore for preventing flow of fluid through the tool. Opening and closing the flow paths is used to select tool function.

In embodiments, a rack and pinion system actuates the ball-type selector valve to open when run-in-hole (RIH) and close when pulled-out-of-hole (POOH). The overall size of the ball-type valve and the relatively short axial travel required by the rack and pinion system to actuate the ball-type valve between open and closed positions permits the overall length of the BHA to be shortened compared to tools having selector valves which rely upon axial movement of a mandrel relative to a sleeve for aligning ports to open and close fluid pathways for selecting tool function. Shorter tools generally result in a lower overall cost for such tools and increase the ease of handling at surface.

In one broad aspect, a selector valve for selectively directing a flow of fluid through a bore of a tool or blocking the flow therethrough comprises a tubular housing having a bore therethrough. A ball valve is located in the housing bore and has an axial fluid passage therethrough. A rack and pinion system is connected between the housing and the ball valve. When the rack is moved relative to the pinion in a first axial direction, the ball is rotated to align the fluid passage with the housing bore in an open position. When the rack is moved relative to the pinion in a second axial direction, the ball is rotated to misalign the fluid passage with the housing bore in a closed position.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a selector valve according to an embodiment taught herein, shown in a closed position;

FIGS. 2 to 6 are cross-sectional views of the selector valve of FIG. 1, illustrating incremental rotation of the selector valve about a pinion from the closed position, shown in FIG. 1, to the fully open position shown in FIG. 6;

FIG. 7 is a cross-sectional view of the valve in the fully opened position of FIG. 6, sectioned to show the rack and pinion system; and

FIG. 8 is a cross-sectional view of the valve in the fully closed position of FIG. 1, sectioned to show the rack and pinion system.

DESCRIPTION

Embodiments taught herein utilize a ball-type selector valve 10 which rotates for opening and closing flow paths for selecting tool function.

In embodiments, a rack and pinion system 12 actuates the ball-type selector valve 10 to open when run-in-hole (RIH) and close when pulled-out-of-hole (POOH). The overall size of the ball-type valve 10 and a relatively short axial travel required by the rack and pinion system 12 to actuate the ball-type valve 10 between open and closed positions permits the overall length of a bottomhole assembly (BHA), in which the selector valve 10 is incorporated, to be shortened compared to tools having selector valves which rely upon axial movement of a mandrel relative to a sleeve for aligning ports to open and close fluid pathways for selecting tool function. Shorter tools are generally reflected in lower overall cost for such tools and ease of handling at surface.

FIG. 1 illustrates a ball-type selector valve 10 assembly according to embodiments taught herein in a closed position. A ball-type selector valve 10 is housed in a bore 14 of a tubular housing 16. The ball-type selector valve 10 is actuated to rotate, and cause an axial fluid passage 18 therethrough to rotate into and out of alignment with the housing bore 14. When assembled in the BHA, the housing bore 14 is contiguous, and therefore fluidly connected to, a bore of the BHA. In the closed position, the ball-type selector valve 10 obstructs the flow of fluid F therethrough.

Having reference to FIG. 6, when the axial fluid passage 18 is aligned with the housing bore 14, fluid flows therethrough, and to the BHA bore therebelow. The BHA is generally deployed using coiled tubing although, as one of skill will appreciate, can also be deployed using jointed tubulars. For simplicity, embodiments are described herein in the context of a coiled-tubing deployed BHA.

Having reference to FIGS. 1 to 8, the tubular housing 16 is a two part, telescoping housing comprising an axially moveable upper portion 22, for operative connection to the coiled tubing and a lower portion 24, for operative connected to the BHA and affixed thereto. Further, the rack and pinion system 12 is operatively connected between the housing 16 and the ball-type selector valve 10 for rotation thereof.

Best seen in FIGS. 7 and 8, the rack and pinion system 12 comprises a rack 26 which is mounted on the housing's upper portion 22 and is axially moveable therewith for rotating the ball-type selector valve 10 about a pinion 28, rotatably supported in the housing's lower portion 24.

In embodiments, the ball-type selector valve 10 is actuated to an open position when weight is applied to coiled tubing and the BHA, such as when the BHA is run-in-hole (RIH) and is actuated to a closed position when tension is applied to the BHA, such as when the BHA is pulled-out-of-hole (POOH).

During a POOH operation, tension applied to the coiled tubing causes an inner mandrel of the BHA operatively connected to the housing's upper portion 22, to which the rack 26 is connected, to slide telescopically uphole, driving the rack and pinion system 12 and causing the ball-type selector valve 10 to rotate about the pinion 28 for misaligning the axial fluid passage 18 therein with the housing bore 14, closing the ball-type selector valve 10 and blocking fluid flow therebelow. With the ball-type selector valve 10 in the closed position, fluid flow thereabove may be diverted to tools positioned above the ball-type selector valve 10, such as an Abrasa-jet cutting head used to cut perforations.

Once perforations are cut, the ball-type selector valve 10 can be opened by applying weight to the coiled tubing to RIH, driving the rack 26 therewith for rotating the ball-type selector valve 10 to align the axial fluid passage 18 therethrough with the housing bore contiguous with the BHA bore, allowing fluid to flow to tools positioned below the ball-type selector valve 10, used for alternate operations, such as to a frac head for fracturing operations.

A tubular sleeve 30 is supported in an upper portion 15 of the housing bore 14. The sleeve 30 has an upper ball seal 32 at a distal end 34 thereof. A retainer spring 36, housed between the sleeve 30 and the upper housing 22, acts on the sleeve 30 to provide sufficient force to bias the sleeve 30 and seal 32 against the ball-type selector valve 10 when the upper housing 22 travels uphole so as to seal thereagainst and prevent fluids and debris from entering a chamber 38 housing the rack and pinion system 12, as shown in FIG. 8.

As best seen in FIGS. 3 and 4, a lower ball seal 37 in the stationary lower housing 24 seals against the ball valve 10 to further prevent fluids and debris from entering the chamber 38.

In an alternate embodiment, the rack and pinion system 12 can be configured to be driven by an internal hydraulic system that uses the stroking action to drive a hydraulic cylinder back and forth to force internal, isolated hydraulic fluid to act on a linkage of the ball-type selector valve 10 to align or misalign the axial fluid passage 18 as described above. The hydraulic system can be designed in a number of different ways, however, generally, the mechanism uses a stroke distance to power the fluid to drive the movement of the ball-type selector valve 10.

Embodiments are also contemplated where RIH closes the ball-type selector valve 10 while POOH opens the ball-type selector valve 10.

FIGS. 2 to 6 illustrate rotation of the ball-type valve about the pinion from the closed position, shown in FIG. 1, to the fully open position shown in FIG. 6. As can be seen, the axial travel of the upper housing 22 relative to the lower housing 24 is delimited, such as by upper and lower shoulders 40, 42 formed on the stationary lower housing 24. An upper shoulder 44, spaced uphole from the distal end 46 of the upper housing 22 engages the upper shoulder 40 when the upper housing 22 is moved axially away from the ball valve 10, for delimiting uphole movement of the upper housing 22. The distal end 46 of the upper housing 22 engages the lower shoulder 42 when the upper housing 22 is moved toward the ball valve 10 for delimiting the movement of the upper housing 22. Thus, rotation of the ball-type selector valve 10 is also delimited, such as to about 90 degrees, from the fully open position to the fully closed position.

FIG. 7 illustrates the ball-type selector valve 10 in the fully opened position however, unlike FIG. 6, is sectioned to show the rack and pinion system 12 as described above.

FIG. 8 illustrates the ball-type valve in the fully closed position however, unlike FIG. 1, is also sectioned to show the rack and pinion system 12 as described above.

When configured in the BHA, the ball-type selector valve 10 separates frac window or ports, such as a blast joint, and a bypass valve below the ball-type selector valve 10 from the remainder of the BHA above. The rotatable ball-type configuration of the selector valve 10 taught herein is in direct contradistinction to the prior art pull-type sliding selector valves, which incorporate the frac window or ports, such as a blast joint, and the bypass valve into one assembly.

The advantages of separating the assemblies include, but are not limited to, cost reduction and ease of replacement of worn components without the need to replace the more costly, complicated assemblies.

In the event the bypass valve is not required or the frac window is not required, embodiments of the ball-type selector valve 10 may be run-in-hole independently for other operations with other tools providing a wider range of utilization. For example, using a tension release packer, as described in U.S. application 62/110,994 to Angman et al, incorporated herein in its entirety, for elimination of the bypass valve, the ball-type selector valve 10 may be run to open and close flow just to the frac window. 

The embodiments in which an exclusive property or privilege is claimed are defined as follows:
 1. A selector valve for selectively directing a flow of fluid through a bore of a tool or blocking the flow therethrough comprising; a tubular housing having a bore therethrough; a ball valve located in the housing bore and having an axial fluid passage therethrough; and a rack and pinion system connected between the housing and the ball valve wherein when the rack is moved relative to the pinion in a first axial direction, the ball is rotated to align the fluid passage with the housing bore in an open position; and when the rack is moved relative to the pinion in a second axial direction, the ball is rotated to misalign the fluid passage with the housing bore in a closed position.
 2. The selector valve of claim 1 wherein the housing is a two-part telescoping housing comprising: an axially moveable upper portion operatively connected to the rack for moving the rack between the first and second axial positions; and a lower stationary portion for rotatably supporting the pinion.
 3. The selector valve of claim 2 wherein the rack is mounted to the upper portion of the housing and is axially movably therewith; and the pinion is rotatably supported in the lower housing and connected to the ball valve for rotation of the ball valve therewith.
 4. The selector valve of claim 2 further comprising: a tubular sleeve supported in an upper portion of the housing bore; seals supported in a distal end of the sleeve; and a spring housed between the upper portion of the housing and the sleeve for biasing the sleeve and seals against the ball valve when the upper housing is moved axially away from the ball valve.
 5. The selector valve of claim 3 further comprising: upper and lower spaced apart shoulders on the housing's lower portion; and an upper shoulder, formed on the housing's upper portion and spaced uphole from a distal end thereof, wherein when the upper housing is moved away from the ball valve, the upper shoulder on the lower portion of the housing engages the upper shoulder on the upper portion of the housing for delimiting movement thereof; and when the upper housing is moved toward from the ball valve, the lower shoulder on the lower portion of the housing engages the distal end of the upper portion of the housing for delimiting movement thereof.
 6. The selector valve of claim 5 wherein moving the upper housing toward the ball valve is the first axial direction and moving the upper housing away from the ball valve is the second axial direction.
 7. The selector valve of claim 5 wherein rotation of the ball valve between the open position and the closed position is delimited to about 90 degrees. 